Structural Insulation Panel Finished (SIPF)

ABSTRACT

The Structural Insulating Panel Finished (SIPF) has a finished external surface and internal surface ready for carrying out of immediate painting and decorating. Introduction of the stud inside a panel construction is with a result of creating a rigid special structure with other elements of the panel. 
     The spray-foam technology is employed in constructing powerful connections between inner and outer layers. As a result of high adhesive qualities of spray-foam, we have strong connections between panels where all lacunas are filled by an insulation layer that provides a highly reliable connection. 
     The innovations discussed above eliminate the need for exterior finish of the panel, reducing time and cost of construction while allowing build houses of two-three floor height. The SIPF panel has an insulation layer of 6″ deep, making it possible to use the product in all climatic zones of the World.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/002,381, filed Nov. 8, 2007.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

“Not Applicable”

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC

P. 15 of the Specification

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the construction panels, compositions and methods for making construction panels and, in particular, to an improved construction panel called in further Structural Insulating Panel Finished—SIPF.

The SIPF is intended for use for the construction of the Energy-efficient objects, based on the Green Homebuilding requirements.

2. Background of the invention

It is known in the art and in the market the Structural Insulated Panels (SIP). There are the most related applications to SIPF.

SIP panels are manufactured in USA by the companies, for example, “INSULPAN” (www.insulspan.com), “PANEL PROS” (www.panelpros.com), and others more than 27 years already.

The system of construction, based on use SIP panels, is most progressive in comparison with traditional system of stick frame construction.

Major disadvantages of SIP panels are necessity of an additional protective and decorative covering an external surface of the panels, and also additional installation of gypsum cardboard (Drywall), necessary for carrying out of painting and decorating of the internal surface of the SIP panels. SIPF panel does not have these disadvantages.

SIPF is intended for use for the construction mostly 1-3 floor Energy-efficient objects, based on the Green Homebuilding requirements.

The SIPF panel has an insulation layer of 6″ deep, making it possible to use the product in all climatic zones of the World: to keep cold, where is hot; to keep heat, where is cold; so, to save the resources of Energy and minimize expenses. The major advantages of the SIPF panel are the following: the price of its manufacture approximately the same as manufacture of the relative analogues while meeting the Green Homebuilding requirements. At the same time, the use SIPF allows to reduce sharply terms of construction in comparison with other types of the wall, ceiling, roofing and flooring panels, because there is no need to spend extra time for an external finish of the panel and the time for internal work on the panel is reduced significantly. Lower cost of construction of buildings is the major criteria and preference for the customer in choice of SIPF for construction technology as well as popularization of Green technology. Mass application of SIPF accelerates promotion of Green technologies resulting in great reduction of CO2 emission into an atmosphere. Owing to simplicity and universality of SIPF, there is no need of high level professionals for its installation. After a short training session, it is possible for two people to raise external walls up to 2000 sq. ft building in one day.

The present invention, overcoming essential limitations of the prior art, represents the Structural Insulated Finished panel which is not only Energy-efficient and easily installed with a high speed of the construction technology. Owing to the original technology SIPF also could be made available to the economic mass production on-site.

BRIEF SUMMARY OF THE INVENTION

The essence of the present invention consists of creating the SIPF panel made on certain (See below) technologies. The SIPF panel has a finished external surface and the internal surface ready for carrying out of painting and decorating. In comparison with SIP panels it lays in a change of an OSB, which usually SIP used for its surfaces, from the external surface of the panel to the finished external surface, for example, LP Smart Side Panel (www.lpcorp.com), Magnesium Board (www.dragonboard.com) or other, that have a decorative outer layer. Instead of OSB, the inner layer of the panel is made out of the surface, which is ready for painting and decoration, for example, Drywall, Magnesium Board or other; instead of expanded polystyrene we are using polyurethane, for example, Bio Based 501 (www.biobased.net) or other. Moreover, instead of using glue to connect OSB and a layer of insulation—will be using gluing characteristics of foaming polyurethane adhesive to force it in the empty space between inner and outer layers of SIPF. This material foams over and fills the empty space between surfaces gluing them together. Leftovers of polyurethane can be easily removed.

It is for the first time that the use of the spray-foam technology is employed in constructing powerful connections between panels. As a result of high adhesive qualities of spray-foam, we have strong connections between panels where all lacunas are filled by an insulation layer that provides a highly reliable connection.

So, in comparison with different types of SIP panels, SIPF does not use any extra layer for insulation, and any extra glue for the connection between outer and inner layers of SIPF.

Using SIPF panels in construction allow for significant reduction of time and cost of construction due to cutting the time needed for installation of the external surface - decorative protective layer as well as preparatory painting and decorating of the internal surface of the panel. So, it sharply reduces expenses for developing of the construction labor and terms of their performance.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWING

FIG. 1 is a top plan view of the SIPF (Drawing 1)

FIG. 2 and FIG. 3 are top back views of the SIPF construction (Drawing 1)

FIG. 4 shows installation of the SIPF on the floor surface (Drawing 2)

FIG. 5 shows connections of the SIPF panels (Drawing 2)

FIG. 6 shows elements of the SIPF ceiling, roofing and flooring panels (Drawing 3)

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a construction panel and a method for making the same, based on U.S. Provisional Patent Application No. 61/002,381, filed Nov. 8, 2007, the entire content of which is hereby incorporated by reference.

DETAILED DESCRIPTION OF THE DRAWINGS

The SIPF panel consists of a rectangular external plate 2, a rectangular internal plate 3 and the insulation layer 1 placed between these plates.

The process of manufacturing SIPF panel consists of forcing Insulation Polyurethane 1 (FIG. 2—Drawing 1) between plates of the outer layer of the panel 2 and the inner layer of the panel 3 (FIG. 2—Drawing 1). After foaming of Polyurethane 1 plates 2 and 3 are reliably fixed among themselves. Surpluses of the Polyurethane 1 will be removed using an electric cutting torch (Electric Hot Wire Foam Cutter). The Wooden Stud 4 (FIG. 3—Drawing 1) is entered in design of the SIPF panel to create bearing skeleton of a building and to provide reliability of connection of panels among themselves.

The dash line (FIG. 1—Drawing 1) is showing the slot around three sizes of the SIPF panel (it means that the Insulation Polyurethane 1 does not reach edges of the panel: at the left—on distance ½ thickness bearing Wooden Stud 4 panels (FIG. 3—Drawing 1), from above and from below—on full thickness of Sill 6 (FIG. 4—Drawing 2) of the floor.

The SIPF panel 5 (FIG. 4—Drawing 2) is established on Sill 6. Glue or nails, or others such as screws, staples, are used as fastening. Secure Connection 10 (FIG. 5—Drawing 2) SIPF panels A & B (FIG. 5—Drawing 2) among themselves provides using T&G (Tongue & Groove) method. Reliability of connections is reached by means of the Insulation Polyurethane 1 laid on all connection, or use of nails.

As shown on FIG. 6—Drawing 3 the Wooden Joist 11 is used for connection between the inner 13 and outer 14 layers of the SIPF panel. The two Metal Joists are used for increasing the bearing capacity of the SIPF panel used for ceiling, roofing and flooring.

Specification of the Details Using in the Drawings:

1—Insulation Polyurethane (Bio Based 501, or other)

2—The outer layer of the panel—LP Smart Panel, Magnesium Board

3—The inner layer of the panel—Drywall, Magnesium Board

4—Wooden Stud

5—SIPF

6—Sill

7—Finishing Nail or Screw

8—Sub floor

9—Joist

10—Connection “Tongue & Groove”

11—Wooden Joist

12—Metal Joist

13—The top layer of the panel for ceiling, roofing and flooring—Magnesium Board

14—The bottom layer of the panel for ceiling, roofing and flooring—Magnesium Board

The Major Terminology is used in the Specification:

SIP—Structural Insulated Panel OSB—Oriented Strand Board

LP Smart Side Panel—is the versatile choice when finishing any style home.

It boasts incredible strength-to-weight ratio. It is so strong you can nail it directly to the studs, speeding up installation, and saving you valuable time.

Magnesium Board—the fire resistant, water resistant, high-impact construction panel that is well-suited for both interior and exterior sheathing applications. With its mold resistant, fire resistant and high impact properties. Bio Based 501—the Class 1, Bio Based Spray Foam Insulation voted “Outstanding green product of the year 2003”. 

1. A construction panel comprising: (a) an outer layer of the panel; (b) an inner layer of the panel; and (c) an insulation layer that is placed between (a) and (b), wherein said an outer layer of the panel has a finished surface; an inner layer of the panel has the surface, which is ready for painting or decoration; an insulation layer is a polyurethane.
 2. The panel of claim 1 wherein the outer layer of the panel has the finished external surface, like LP Smart Side Panel, Magnesium Board, or other, which has a decorative outer layer.
 3. The panel of claim 1 wherein the inner layer of the panel is made out of the surface, which is ready for painting and decoration, similar to Magnesium Board, Drywall or other.
 4. The panel of claim 1 wherein the insulation layer is used the gluing characteristics of foaming expanded polyurethane adhesive to force it in the empty space between inner and outer layers of the panel; this material foams over and fills the empty space between surfaces gluing them together, and as a result of high adhesive qualities of spray-foam will be a strong connections between panels where all lacunas are filled by an insulation layer that provides a highly reliable connection.
 5. The panel of claim 1 wherein the insulation layer does not reach edges of the panel, and it is showing the slot around three sizes of the panel, when the fourth side of the panel is a stud or joist, to provide reliability of connection of panels among themselves, and to create, in conjunction with the floor and ceiling beams, the bearing skeleton of a building.
 6. The panel of claim 1 wherein the stud is only made out of the materials which are rotting resistant, corrosion resistant, and mold resistant; the outer and the inner layers of the panel are made out of the materials, like Magnesium Board, that is the panel for foundation, which is possible to use to any underground constructions (for example, basements).
 7. The panel of claim 1 wherein the two metal joists are used for increasing the bearing capacity of the panel used for ceiling, roofing and flooring.
 8. The panel of claim 1 wherein the additional increase of the load capacity of the panels is achieved through soldering of metal studs between in the outer and inner layers of the panel used for ceiling, roofing and flooring in time of the foaming and hardening of polyurethane.
 9. The panel of claim 1 wherein the connection between the outer and inner layers of the panel takes place during the foaming and hardening of polyurethane, which is gluing them together and producing the insulation layer of the panel at the same time.
 10. The panel of claim 1 represents the panel which is Energy-efficient and easily installed with a high speed of the construction technology, and also could be made available to the economic mass production on-site. 